Entrance structure

ABSTRACT

There is provided a new and improved entrance system for a building which permits a latitude of design by the architect. The system includes a door formed of butt joined vertical and side rails, the rails each having side pockets extending beyond spaced webs thereby forming glazing pockets. Longitudinal parts on the tubular structures of the rails defune longitudinal screw splines. Twisting and shear stresses between the rails are reacted through a joint block of general T-shape having a body portion fitting within the glazing pocket of one rail and a tongue portion fitting within the tubular structure of the abutting rail. Screw fasteners extend through the joint block and the rails to secure the rails together.

United States Patent [191 Biebuyck et al.

[ June 11, 1974 ENTRANCE STRUCTURE [75] Inventors: Lawrence F. Biebuyck,Dallas, Tex.;

Eugene Hubbard, Niles, Mich.

[73] Assignee: American Metal Climax, Inc., New

York, N.Y.

22 Filed: June 8,1972

21 Appl. No.: 260,977

Related US. Application Data [62] Division of Ser. No. 25,457, April1970,

[52] US. Cl. 403/187, 403/260 [51] Int. Cl. Fl6b 7/18 [58] Field ofSearch 287/l89.36 H, 189.36 C, 287/l89.36 R; 52/656, 731, 239, 499, 475,239; 49/501 [56] References Cited UNITED STATES PATENTS 2,706,543.4/1955 Kammerer 52/656 3,147,5l8 9/l964 Horgan... 52/731 3,299,596l/l967 Neal 52/731 Proud 52/73l Crossman 52/731 Primary ExaminerReinaldoP. Machado Attorney, Agent, or Firm-Mason, Kolehmainen, Rathburn & Wyss[57] ABSTRACT There is provided a new and improved entrance system for abuilding which permits a latitude of design by the architect. The systemincludes a door formed of butt joined vertical and side rails, the railseach having side pockets extending beyond spaced webs thereby formingglazing pockets. Longitudinal parts on the tubular structures of therails defune longitudinal screw splines. Twisting and shear stressesbetween the rails are reacted through a joint block of general T-shapehaving a body portion fitting within the glazing pocket of one rail anda tongue portion fitting within the tubular structure of the abuttingrail. Screw fasteners extend through the joint block and the rails tosecure the rails together. I

4 Claims, 22 Drawing Figures 3; L saznsnrs 816 011 PATENTEDJHM 1 1 1914ENTRANCE STRUCTURE The present invention is a division of our co-pendingapplication Ser. No. 25,457 filed Apr. 3, 1970.

The present invention relates to an imporved entrance structure, andmore specifically to a coordinated system of doors, entrance frames,graphic identification, and hardware to provide an entrance arrangementhaving a wide latitude with regard to the combination and design inbuilding entrances. The system is particularly adapted to be assembledfrom extruded aluminum construction elements.

Heretofore commercially available aluminum doors and entrances havegenerally been highly standardized, mass produced products which lookand act very much like the doors made of other materials. Aluminumdoors, particularly, are strong enough to withstand heavy traffic if thedoor is not abused. It has definite advantages in that it provideslittle obstruction to a clear view of the interior of the building fromthe street. Although it has somewhat marginal weathering properties,these may be of little importance if the doors are likely to be open alarge part of the time. Many of these doors go into building facadesthat do not warrant, and do not get, the benefit of architectural designservices. However, there are buildings such as schools, colleges, publicauditoriums, recreation buildings, churches, and public buildings of allkinds wherein the ordinary commercial aluminum door is not satisfactory.These buildings are always architect-designed and their entrances are anintegral part of their design compositions. The commercially availabledoor does not give the monumental entrance the visual impact that itmust have if it is to be part of the building design composition. Doorsin these buildings get heavy traffic, and sometimes abusive traffic.They must be strong, and look strong.

To provide an entrance, doors mustbe mounted in frames. Historically,the frames have been developed at different times as completelyindependent products. As they stand commercially today, the doors of anymanufacturer may be mounted in the frames of any other manufacturerwithout any loss of design impact. Door hardware has been anotherweakness of the commercial aluminum door as applied to monumentalentrances.

It has been recognized that commercial doors are often too light inappearance and too weak in structure for buildings of institutionalcharacter. Some manufacturers have responded by making a commercial doorwith wide stiles. Other manufacturers have brought out heavier walledportions of commercial doors, and have given them various labels such asinstitutional doors. These beefed up doors do look stronger, and mayactually be stronger. But they offer the architect no design optionsover the conventional commercial door.

Accordingly, it would be advantageous if an entrance structure wasoffered specifically designed to set off the architecture of thebuilding, and if the architect had'options as to the character andproportion of the pushpull hardware. Moreover, it would be desirable forthe architect in buildings of monumental character to have the option ofdesigning his own doors to complement his building. Thus, it would bedesirable to provide a system of elements which may be combined toprovide custom doors and entrances for buildings.

Accordingly, one object of the present invention is to provide a new andimproved entrance structure which has the above mentioned advantages.

A further object of the present invention is to provide a new andimproved entrance structure which provides an architect with a latitudeof design combinations.

Yet another object of the present invention is to provide a new andimproved door.

Still another object of the present invention is to provide a new andimproved door which may be custom designed with a wide latitude ofdesign combinations.

Still another object of the present invention is to provide a new andimproved door structure which is sturdy and rugged in construction.

In accordance with these and many other objects of the presentinvention, there is provided a new and improved entrance structure whichpermits wide latitude with regard to the combination of the componentsto the architect. An improved door system is provided wherein the dooris formed of interconnected vertical and side rails. The rails areformed of a pair of spaced side faces and a pair of spaced transversewebs, the side faces including legs projecting outwardly ofthe webs todefine pockets. The webs and portions of the faces therebetween form atubular structure, and longitudinal parts at the corners of the tubularstructure define longitudinal screw splines. The improved door includesa corner joint wherein the vertical and side rails are butt joinedtogether by a joint block of generally T- shape having a body portionfitting within the pocket of one rail and having a tongue portionfitting within the tubular structure of the other rail. Thus, shear andtwisting loads of the door are carried in the joint block. The buttfitted joint may be secured in any conventional manner as by screws.However, the joint comers may additionally be welded if desired.

For a better understanding of the present invention reference may be hadto the accompanying drawings wherein:

FIG. 1 is an elevational view of a new and improved door according tothe present invention;

FIG. 2 is a detailed view. of a comer joint structure of the door ofFIG. 1, taken along detail 2 of FIG. 1;

FIG. 3 is a cross sectional view of the upper rail of the door ofFIG.'1, taken along line 3-3 of FIG. 1;

FIG. 4 is a comer detail of the door ,of FIG. 1, taken along detail 4 ofFIG. 1

FIG. 5 is a cross sectional view of the lower rail of the door of FIG.1, taken along line 5--5 of FIG. 1;

FIG. 6 is a cross sectional view of one vertical door stile, taken alongline 6-6 of FIG. 1;

FIG. 7 is a cross sectional view of the other vertical stile of the doorof FIG. '1, taken along line 7 -7 of FIG. 1;

FIG. 8 is an exploded view of a lower corner joint wherein the verticalrail is through;

FIG. 9 is an exploded view of an upper comer joint' wherein the verticalrail is through;

FIG. 10 is an elevational view of a typical door with through horizontalrails;

FIG. 1 l is an exploded view of the lower comer detail 11 ofFIG. l0,illustrating a typical through horizontal lowerrail joint;

FIG. 12 is an exploded view of the upper corner joint 12 of FIG. 10,illustrating a typical through upper rail joint;

FIG. 13 is a cross sectional view of a typical door rail illustrating adifferent glazing arrangement wherein the glazing panel is offset fromthe center of the door;

FIG. 14 is a cross sectional view of a typical door rail illustrating aprojecting glass stop compatible with the present system;

FIGS. 15 and 16 represent two door structures composed in part ofvertical panels illustrating the versatility of the present entrancesystem;

FIG. 17 is a cross sectional view of the door of FIG. 15, taken alongline 1717 thereof;

FIG. 18 is a cross sectional view of the door of FIG. 16, taken alongline 18-18 thereof;

FIG. 19 illustrates a top rail assembly taken along line 19-19 of FIG.16;

FIG. 20 represents a top rail assembly taken along line 2020 of FIG. 16;

FIG. 2l-illustrates a lower rail assembly taken alon line 21-21 of FIG.16; and

FIG. 22 illustrates a horizontal rail'structure wherein the planks gothrough and typically shown as 2222 of FIG. 15;

Referring now to the drawings, and particularly to the embodiment ofFIGS. 1 through 7, there is illustrated an improved door 100 accordingto the present invention. As therein illustrated, the door, for purposesof illustration, has a through upper rail assembly 101, a lower railassembly 102, and two side rail assemblies 103 and 104. Glass or othersuitable panel 112 is in the opening formed by the interconnected railassemblies 101, 102, 103 and 104.

The rails make up the basic structure of the door, and are generallyuniversal and interchangeable, capable of being used as verticals,horizontals, or intermediates. A typical. construction element forming arail assembly is illustrated in FIG. 5. As therein illustrated, aconstruction element 105 is formed by extrusion or other suitable meansof suitable material such as aluminum. The extrusion element 105 has agenerally tubular structure defined by spaced transverse webs 105a and105b, and spaced interconnecting side faces 1050, 105d. The side facesinclude legs 105e, l05f, 105g and'105h projecting outwardly of the webson both sides thereof to form pockets 106, 107. The interconnected websand the portions of the side faces therebetween form a tubular structureto provide strength and rigidity to the construction elements.Longitudinal parts at the corners of the tubular structure definelongitudinal screw splines 113 for use in the assembly. These screwsplines 113 have flattened tops 105k to provide solid bearing for theheads of assembly screws. As indicated,'the parts forming the screwsplines 113 are filleted directed to the heavy side faces 1050, 105d, aswell as to the webs 105a, 105b, serving to provide stiffness andtransfer of stress at the joints between the rails and between thescrews .a ..si a s 05 v The ebs- .5. and 105b may be made thinner thanthe faces in order to conserve material and in recognition that theycarry comparatively light loads and are hot exposed tov abuse. In theinterest of universal use, the glazing pocket 106, 107 are provided ontheir inner surface with weathering pockets or glazing channels 108, andwith longitudinally extending inwardly projecting V- shaped ribs 109.Along the bottom of the bight portion of the pockets 106 and 107 are oneor more longitudinally extending dove-tailed ribs 110. The glazingchannels 108, and the ribs 109 and 110 cooperate to support a suitableglazing means as more fully described later. However in the illustratedembodiment there is provided a pair of glass stops 111 for supporting aglass panel 112, FIG. 1, within the door. Thus, the basic rail extrusionused in the side rails and lower rail are all similar to thatillustrated in FIG. 5, except for their availability with standard facewidths, such as 3, 4 A, and 6 inches. Rails of such various face widthsare illustrated in FIG. 6, element 115, and in FIG. 7, element 116.Elements 115 and 116 are similar to construction element 105 except forthe difference in the face length.

To provide for glazing .of the door after assembly thereof, the upperrail (and intermediate rails if used) have a removable face. As hereinillustrated, referring to FIG. 3, there is provided a constructionelement 120 including webs 120a and 120k and side portions 120c and120d; One side portion 1200, however, includes a removable face 121 anda connecting portion 12% interconnecting theweb's 120a and 12% andfilled to its adjacent screw splines 1 13. The lower projecting leg ofthe side face 120d is provided with a glazing channel 108; since theupper projecting leg of the removable face 121 will never be used tosupport glazing means, only the lower projecting end thereof is providedwith the glazing channel. However, if the rail were to be used as anintermediate, then a glazing channel would be provided on bothprojecting legsof the removable face. To secure the removable face 121to the construction element, there is provided an interlocking tongue120m fitted within a groove 121a of the'face and extending upwardly fromthe outer portion of the screw splines 113. Additionally, there isprovided alongitudinally extending transverse flange 12le extendinginwardly from the removable face 121 and seated against the upper one ofthe webs 120a, being secured in place by suitable screws 122.Advantageouly the removable face 121 may be removed only when the door100 is open, and presents an unbroken outward face with no weatheringjoints, eliminating the possibility of vandalism and tampering.

Any door system must of coursebe provided with stile caps. Typical stilecaps are shown in FIGS. 6 and 7. Referring to FIG. 7, there isillustrated a stile cap 125 completely covering the edge of the rail116, necessary in order to, cover the open end of a through runninghorizontal rail, such as the upper rail 101. The stile cap 125 isprovided with two projecting legs 125a having snap-lock detents l25bsecured within the pocket of the element 116 over the ribs 109 thereof.

FIG. 6 illustrates a stile cap 126 secured to the glazing pocket of theelement 1 15. The stile cap 126 is provided with the projecting legs126a snapping over the ribs 109 on the construction element. Theconstruction 126 also covers the entire edge of the element 115 in likemanner as the stile cap 125 covers the end cut of any through runninghorizontal rails. The stile cap 126 is provided with weathering pockets127 for retaining suitable weather strip 128.

To transmit shear and torque loads between abutting vertical andhorizontal rails there is provided a joint block used at each of therail joints. Thus the joint blocks relieve the asembly screws of shearloads, leaving them stressed essentially in tension. A different jointblock is used for joints on rails having different face dimensions;however, all of the joint blocks in accordance with the illustratedembodiment may be machined from the same extrusions. A typical jointblock is illustrated, for example, in FIG. 8 wherein there isillustrated a lower horizontal rail abutting against a through vertical,similar to that illustrated in FIGS. 1

and 4. Referring now to FIG. 8, there is illustrated a joint which mayinclude a side rail assembly 104 extending through, and a lower railassembly 102 abutting against the rail assembly 104. A joint block 130according to the present invention interconnects the two rails. Morespecifically, the joint block 130 is formed in general T-shape, with thebody portion 130a thereof dimensioned to closely fit within the glazingpocket 106 of the through running rail 104. A tongue portion 13% isdimensioned to closely fit between the screw splines 113 of the abuttingrail assembly 102. Four screw fasteners or connectors 132 extend throughthe web of the through rail 115, through apertures 1300 in the jointblock 130, and into the respective screw splines 113 of the rail 105,More specifically, the outer web 115a of the rail 115 is provided with aplurality of spaced apertures 134 sufiiciently large to pass the head ofthe screws 132, and alignedscrew openings 135 are provided in the innerweb lb through the screw splines 113 of the element 115 to receive theshank of the screws 132. The aligned apertures 134 and 135 areshopformed so that by the selective use of the desired apertures,butting rails of different widths may be used. Thus it will be seen by acomparison with a typical upper joint having a through vertical that ajoint block 137 of a shorter length may be used if a rail of narroweface abuts the through rail.

More specifically, there is illustrated typical vertical rail 138extending through, being abutted by a typical upper horizontal railassembly 139. As heretofore described the rail assembly 139 has aremovable face 140 snapped thereto and secured by suitable set-typescrews 122. The through rail 138 is formed of outer and inner transversewebs 138a and 138b, and inner and outer side faces 1380 and 138d. Thus,there is formed the pair of pockets 106 and 107 for glazing or otherpurposes. The joint block 137 includes the body portion 137a dimensionedto fitwithin the pocket 106 of the rail 138, and includes the tongueportion l37b dimensioned to fit between transverse webs 139a and 13911of the rail assembly 139. The plurality of screws 132 extend throughselected ones of the larger apertures 134 in the outer web 1384, and theheads of the screws 132 seat on the flat surfaces of the screw splines113, extending through the apertures 135 of the inner web 138b, and aresecured within the screw splines 113 of the rail assembly 139.

As heretofore described, a similar construction is used with throughhorizontals as illustrated in FIGS. 10-12. More specifically, in FIG. 10is illustrated a door 142 formed of upper and lower rails 143 and 144and side rails 145 and 146. The horizontal rails 143 and 144 arethrough, and the vertical rails 145 and 146 butt against the throughrails. A typical rail joint for a lower rail is illustrated in FIG. 11wherein the same connector block 137 is used to carry the shear andtorque loads between the rails 144 and 146. A typical upper connectionis illustrated in FIG. 12 wherein there is provided the upper rail 143having a removable face 147 in like manner as heretofore described. Thesame joint block 137 carries the shear and torque load at this joint.

It will be seen that a door according to the present invention may bedesigned with through verticals, with through horizontals, or acombination of these. In addition, all of the members may be of any oneof a number of difierent stock widths to provide different face widthsto the door rails. Moreover, intermediate horizontals may be combinedwith doors of either type.

Further design latitude is afforded by the provision of a system ofvarious glazing stops. A typical center glazed arrangement hasheretofore been described. A typical offset arrangement is illustratedin FIG. 13, and a typical projected glass arrangement is illustrated inFIG. 14. Moreover, the glass stops may be the same surface texture andcolor as the'rails themselves, or the glass stops may be a different orcontrasting finish thus affording further design latitude with thestructure.

Referring to FIG. 13 there is illustrated a door rail 148 having aglazing pocket 149 and a single glass stop 150 providing for offsettingof a panel 151 relative to the center line of the door. FIG. 14illustrated a projected glass on the door wherein the door rail 148 isprovided with a pocket 149 supporting a set of interconnected glassstops 152 and 153 so that a panel 154 is projected beyond the sidesurfaces of the rail 148.

In addition to the design latitude afforded by a selection of rails andstops, there is provided planks for use with the system. The planksprovide at one edge the details of the basic rails, and will acceptglass or panels in the samemanner as the rails. The opposite edge of theplanks provides an interlock either with another plank or with a typicalrail member. The walls of the planks may be thinner than the walls ofthe rails in order to save metal and weight and is permissable in viewof the fact that the planks are not needed as part of the basic doorstructure. Moreover, the planks are provided with various surfaceconfigurations and may include either a ribbed face arrangement, or asubstantially plain arrangement with spaced grooves, or any otherdesired surface texture. The plank arrangements are best illustratedin-the door embodiments of FIGS. 15 through 22.

Referring first to the embodiment of FIG. 15, there is illustrated adoor arrangement wherein the planks on the surface of the door extendthrough, with neither the upperor lower rails showing. In thisarrangement a different rail configuration for the upper and lower railsis used. In FIG. 16 there is illustrated an arrangement wherein theupper and lower rails of the door structure extend through, and theplanks abut against the upper and lower rails.

Referring to the embodiment of FIGS. 15, 17 and 22, there is illustrateda typical plank shown as of the rib design. As therein illustrated, theplank 160 includes a pair of spaced side faces 161 and 162,interconnected by transverse webs 163 and 164. The side faces 161 and162 extend past the transverse webs so that at one edge there is formeda pocket 165 resembling the pockets 106 and 107 of the door rails, andwhich will accept glass and other panels in the same manner as therails. The opposite edge of the plank 160 provides interlocking portions166 which interlock into an adjacent pocket either with another plank160 or with a typical rail member. Screw splines 167 are provided alongthe transverse webs intermediate their length to facilitate assembly ofthe planks into the door.

Referring now to FIG. 15 there is illustrated an embodiment or design ofa door 170 incorporating a plurality of planks 160. As thereinillustrated, the door 170 includes a pair of spaced side rails 171 and172 interconnected by special horizontal rails 173, FIG. 22. Thehorizontal rail 173 has a portion of its faces cut off in order toreceive the through facing of the planks 160. More specifically, thehorizontal rail 173 includes spaced side portions 174 and .transversewebs 175 which together form a generally tubular structure. Screwsplines 176 are filleted into the side portions and webs 174 and 175.The connection between the verticals and horizontals now may be madewith a suitable joint block in like manner as heretofore described.

In the embodiment of FIG. 15, where planks 160 are used to produce fullpanel doors, it is necessary at some point in the assembly for theglazing edge of a plank to adjoin the glazing edge of either anotherplank or a rail member. For this purpose there is provided a reverser177, FIG. 17, which re-produced the details of the plank interlocks inboth directions, fitting into the recesses at the glazing edges of theplanks and rails. The completed door is, of course, then finished offwith suitable stile caps, such as stile caps 125 and 126.

It will be seen that in the embodiment of FIGS. 15,

i 17 and 22, the side faces 161 and 162 of the planks 160 extendthrough, from the top to the bottom. Thus the upper and lower portionsof the transverse webs 163 and 163 will be coped out to fit over thehorizontal rails 173. Screw fasteners 178 will pass through the innerweb of the horizontal rails 173 into the screw splines 167 of each plankto secure the planks and rails togethen FIGS. 16, 18 and 19 to 21illustrate an embodiment wherein the upper and lower rails extendthrough, and wherein a section of glazing'is incorporated into the door.As therein illustrated there is provided a door 180 formed by a pair ofside rails 181 and 182 and upper and lower horizontal rails 183 and 184.The door 180 is formed of a plurality of planks 185 and a panel 186 ofglass or other suitable material. The planks 185 are similar to theplanks 160 heretofore described, except as to the surface configurationor finish, each formed of side faces and transverse webs formingsuitable glazing pockets 187. Suitable glass stops 188 are used in thepockets 187 containing the glazing panel.

It will be seen that a door design embodying a glass panel does notrequire the use of a reverser, such as was used in the embodiment ofFIGS. 15, 17 and 22. The glass panel 186 may be assembled last, so thatthe planks 185 may be assembled from both the ends of the door siderails 181, 182 thus eliminating the need for the reverser. Moreover, itwill be seen that in the illustrated embodiment wherein the horizontalmembers run through, the planks 185 are square cutand butted against thehorizontal rails 183 and 184. The screw fasteners 178 extending throughthe inner web at the horizontal rails and into the screw splines 176 ofthe planks 185 secure the planks to the horizontal rails 183 and 184.

The doors of the present entrance system are designedto accept many ofthe standard hardware components. While the entrance system according tothe present invention is largely an appearance design to give thearchitect versatility in his design of the en trance structure from astock series of extrusions, suitable hardware must be available topermit maximum latitude to the designer. Accordingly, the present seriesof doors according to the present invention will accept many suitablepanic devices, door closures, door operators, hinges, pivots, push-pullhardware and the like to considerable advantage. I

Although the present invenion has been described by reference to severalembodiments thereof, it will be apparent that numerous othermodifications and embodiments will be devised by those skilled in theart which will fall within the true spirit and scope of the presentinvention.

What is claimed as new and desired to be secured by Letters Patent ofthe United States is:

1. A joint block assembly for use in an entrance door system comprising:

first and second rails, said first rail running through and said secondrail being in butt fitting relation to said first rail, each of saidrails including a pair of spaced transverse webs interconnected by apair of spaced side faces defining a tubular structure, each of saidside faces having end portions extending beyond each of the webs to forma pair of glazing pockets, and longitudinal parts along each of thecorners formed by said webs and side faces to define longitudinal screwsplines,

a joint block of generally T-shape having a body portion to fit withinthe glazing pocket of said first rail and having tongue portioninsertable into the tubular structure of said second rail between thelongitudinal screw splines,

a plurality of fastening means extending through the web portions ofsaid first rail and the body portion of said joint block on oppositesides of said tongue portion and threaded into said longitudinal screwsplines of said second rail.

2. A joint block assembly as set forth in claim 1 wherein each of thelongitudinalscrew splines in said first rail has a plurality of'apertures transverse to the said screw splines for selectively receivingsaid plurality of fastening means.

3. A joint block assembly as set forth in claim 3 wherein each of saidlongitudinal screw splines on said first rail includes spaced engagingflanges to form a slot therebetween, said flanges having flattened topsurfaces in order to receive the head of said fastening means.

4. A joint block assembly as set forth in claim 1 wherein said. firstrail is a vertical rail and said second rail is a horizontal rail.

1. A joint block assembly for use in an entrance door system comprising:first and second rails, said first rail running through and said secondrail being in butt fitting relation to said first rail, each of saidrails including a pair of spaced transverse webs interconnected by apair of spaced side faces defining a tubular structure, each of saidside faces having end portions extending beyond each of the webs to forma pair of glazing pockets, and longitudinal parts along each of thecorners formed by said webs and side faces to define longitudinal screwsplines, a joint block of generally T-shape having a body portion to fitwithin the glazing pocket of said first rail and having tongue portioninsertable into the tubular structure of said second rail between thelongitudinal screw splines, a plurality of fastening means extendingthrough the web portions of said first rail and the body portion of saidjoint block on opposite sides of said tongue portion and threaded intosaid longitudinal screw splines of said second rail.
 2. A joint blockassembly as set forth in claim 1 wherein each of the longitudinal screwsplines in said first rail has a plurality of apertures transverse tothe said screw splines for selectively receiving said plurality offastening means.
 3. A joint block assembly as set forth in claim 3wherein each of said longitudinal screw splines on said first railincludes spaced engaging flanges to form a slot therebetween, saidflanges having flaTtened top surfaces in order to receive the head ofsaid fastening means.
 4. A joint block assembly as set forth in claim 1wherein said first rail is a vertical rail and said second rail is ahorizontal rail.